Head protector

ABSTRACT

A headgear enhancer or head protector of a molded thermoplastic elastomer (TPE), which may include a styrene ethylene butylene styrene (SEBS) material to provide desired resiliency for comfort, force distribution, and protection while also providing suitable molding characteristics related to management of flash, demolding, and deforming. The head protector may include a plurality of elements molded in a network, mesh, or grid of connected polygons forming a single unitary construction with an outer diameter of the elements ranging from about 6 mm (¼ inch) to about 16 mm (⅝ inch). The elements are formed of a material having a durometer range from 40-90 on the Shore A Hardness scale. The head protector may be a headband having a width of 2-10 cm with an open top or crown and bottom and may be worn beneath a helmet or cap, such as a baseball cap or water polo cap.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of commonly owned andcopending U.S. application Ser. No. 15/401,589 filed Jan. 9, 2017. Thisapplication is also a continuation-in-part of commonly owned andcopending U.S. application Ser. No. 29/664,287 filed Sep. 24, 2018,which is a continuation in part of commonly owned and copending U.S.application Ser. No. 15/401,589 filed Jan. 9, 2017, the disclosures ofall of which are hereby incorporated by reference in their entirety.

TECHNICAL FIELD

This disclosure relates to a head protector or protective headgearenhancer for wearing under a hat, cap, helmet, mask, or similarheadgear.

BACKGROUND

Protective headgear and similar protective equipment often includes ahard outer shell with interior padding to reduce and/or distribute theforce of an impact and reduce the potential for injury to the user.However, recent data suggests that traditional protective gear may beinsufficient to reduce the occurrence of concussion or other mildtraumatic brain injury. Furthermore, some sports, such as water polo, donot traditionally use headgear designed to mitigate impact forces and/orreduce the incidence of concussion.

SUMMARY

Embodiments according to the disclosure may include a molded protectoror enhancer made of a thermoplastic elastomer (TPE), which may include astyrene ethylene butylene styrene (SEBS) material to provide desiredresiliency for comfort, force distribution, and protection while alsoproviding suitable molding characteristics related to management offlash, demolding, and deforming. According to one embodiment, a headprotector comprises a plurality of elements molded in a grid orconnected geometric shapes with an outer diameter of the elementsranging from about 6 mm (¼ inch) to about 16 mm (⅝ inch). The elementsare formed of a material having a range from 40-90 durometer. Theelements form a pattern containing openings of at least ⅜ of an in inchin width. The elements may have either a solid, generally homogeneouscross-section or may be made of a material providing sponge-likecross-section with regular or irregular pockets or cells. The headgearor enhancer may be constructed of natural or synthetic rubber includingTPE, SEBS, SEPS, or other polyolefinic rubber, EPDM rubber, silicone, orKRATON polymers. In one or more embodiments, the headgear or enhancerweighs between 2-9 ounces. The headgear may be configured for securingto a mask or helmet to provide additional cushioning and relatedprotection to the forehead of a user. Alternatively, the headgear may beconfigured to conform to the head of the user and be worn under a hat,cap, or similar headwear.

In one or more embodiments, the headgear or enhancer may be configuredto conform to a user's head and be made of resilient material so that itremains in place during use without requiring securing straps. Thisfacilitates use under headwear such as a baseball cap, water polo cap,or similar headwear to provide additional cushioning and/or protectionfrom impact forces. The material provides a customizable fit thatprovides additional protection for the head and a comfortable fit to theuser. Embodiments may also include protectors or enhancers for variousother body parts, such as the hand/wrist, for example.

In one embodiment, a protective headgear comprises a network of moldedsegments forming a single unitary construction of connected polygons,the network configured to form a headband having a width of between 2-10cm with an open top and bottom, the segments molded of a resilientmaterial and having an outer diameter ranging from 5-17 mm and ahardness ranging from 15-60 Shore A Hardness scale.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the claimed subject matter are described indetail with reference to the following figures. The drawings areprovided for purposes of illustration only and merely depict typical orexample embodiments. These drawings are provided to facilitate thereader's understanding and shall not be considered limiting of thebreadth, scope, or applicability of the claimed subject matter. Itshould be noted that for clarity and ease of illustration these drawingsare not necessarily made to scale.

Some of the figures included herein illustrate various embodiments fromdifferent viewing angles. Although the accompanying descriptive text mayrefer to such views as “front”, “rear”, “top,” “bottom” or “side” views,such references are merely descriptive and do not imply or require thatthe claimed subject matter be implemented or used in a particularspatial orientation unless explicitly stated otherwise.

FIG. 1 is a left side view of a head protector or headgear enhancerconstructed and assembled in accordance with one embodiment, shown inposition as worn by a user.

FIG. 2 is a bottom perspective view of the inside of the top of the headprotector of FIG. 1, showing a grid or network of resilient elementsmolded in a unitary construction.

FIG. 3 is an angled back view of the head protector of FIG. 1illustrating a pattern in the shape of an X which continues from thefront of the headgear to the back of the headgear.

FIG. 4 is a front view of the head protector of FIG. 1.

FIG. 5 is a right side view of the head protector of FIG. 1,illustrating that the back side of the headgear is configured to theback of a head while the front allows for an opening so a user can see

FIG. 6 is a rear view of the head protector of FIG. 1.

FIG. 7 is a right side elevational view of the head protector of FIG. 1.

FIG. 8 is a cross-section of a representative element for protectivegear having a circular shape with a sponge-like material having an outerdiameter of between about 6 mm and about 16 mm.

FIG. 9 is a cross-section of a representative element for protectivegear having a circular shape with a generally uniform material having anouter diameter of between about 6 mm and about 16 mm.

FIG. 10 is a cross-section of a representative element having arectangular shape with a generally uniform or homogeneous material.

FIG. 11 is an upper left side isometric view of a second embodiment of amolded head protector according to the disclosure.

FIG. 12 is a front view of the second embodiment of the head protector.

FIG. 13 is a side view of the second embodiment of the head protector asworn by a user.

FIG. 14 is an upper left side isometric view of a third embodiment ofthe head protector according to the disclosure.

FIG. 15 is a front view of the third embodiment.

FIG. 16 is a side view of the third embodiment.

FIG. 17A illustrates a protector or headgear enhancer according to oneembodiment of the disclosure.

FIGS. 17B and 17C illustrate side and rear views, respectively, of theembodiment of FIG. 17A installed in a baseball catcher's helmet.

FIGS. 18-20 illustrate alternative embodiments of a protector orheadgear enhancer according to the disclosure.

FIG. 21A illustrates another embodiment of a protector or headgearenhancer according to the disclosure;

FIG. 21B is a rear view illustrating the headgear enhancer embodiment ofFIG. 21A installed in a baseball catcher's or umpire's mask.

FIG. 21C is a front view illustrating the embodiment of FIG. 21A in usein a baseball catcher's or umpire's mask.

FIG. 22 is an alternative embodiment of a protective gear enhancerconfigured to be worn over the wrist of a user according to thedisclosure.

DETAILED DESCRIPTION

As generally depicted in FIGS. 1-7, one embodiment of a protectiveheadgear enhancer or a head protector 10 for protection of the humanhead, having a network of deformable elements is shown. FIGS. 1-7 showan embodiment that may be molded to have single, unitary construction ofvarious types of natural or synthetic rubber or silicone, which mayinclude TPE, SEBS, SEPS, or other polyolefinic rubber, EPDM rubber, orKRATON polymers, for example. The elements that form the protectivenetwork or mesh have a hardness as measured by a durometer of between40-90 on the Shore A Hardness scale. In one embodiment, the headprotector 10 ranges from 2-9 ounces in weight to provide suitablecomfort and associated protection from impact forces. In one exampleembodiment, the elements form a mesh or network pattern 20 in the shapeof an X. In other embodiments, the elements form connected polygons suchas squares, rectangles, trapezoids, etc.

In the embodiment of FIG. 1, at least some of the elastomeric elementsform a pattern 20 in the shape of an X around a circular element 15 inthe center of the head, each containing openings of at least 9.5 mm (⅜inch) in width 25. FIG. 1 also shows how the head protector 10 fitssecurely on a head without requiring straps.

Referring to FIG. 2, the interior of the top of the device, has acircular element 15 in the center and a network of elements extendingoutward across the top of the headgear 10, forming a pattern 20 in theshape of an X. FIGS. 3 and 6 depict a back view looking through theopenings of at least 9.5 mm (⅜ inch) in width 25. The X pattern 20continues from the front to the back of the head gear. FIG. 4 is a frontview and FIG. 5 is a right side view of the head gear embodiment ofFIG. 1. FIGS. 4-5 illustrate that the back side of the headgear isconfigured to cover the back of a user's head, while the front allowsfor an opening for the face. FIG. 7 is a right side elevational view ofthe headgear, further illustrating that the back side is longer than thefront side, as there is a slight downward slope from the center of thedevice to the front. FIGS. 8-10 depict cross-sectional views ofrepresentative elements forming a single, unitary construction of themolded headgear. FIGS. 8-9 illustrate elements having circularcross-sections 30 and FIG. 10 illustrates elements having a rectangularcross-section 35. Depending on the particular application andimplementation, elements of a single enhancer or protector may havedifferent cross-sectional shapes and/or sizes. FIG. 8 illustrates across-section of an element molded with a sponge-like interior with theouter diameter of the elements ranging from about 6 mm (¼ inch) to about16 mm (⅝ inch) 40. FIGS. 9-10 illustrate elements having a generallyuniform or solid cross-section.

FIG. 11 shows a second embodiment of a head protector identified asreference 11. Head protector 11 is designed to protect the circumferenceabout the head defined by the upper and lower boundaries of theforehead, temples on both sides of the head, and the crown of the headabove the upper boundary of the forehead. Head protector 11 uses anetwork of geometric shapes that are for the most part either triangularelements 16 or rectangular elements 18. Rectangular elements 18 protectthose portions of the head that is relatively smooth while triangularelements 16 protect those portions of the head that angles more sharply.The combinations of triangular elements 16 and rectangular elements 18may be altered to accommodate varying head shapes from children toadult. The edges of a triangular element 16 or a rectangular element 18have a durometer of 15-60 on the Shore A Hardness scale. The triangularelements 16 and rectangular elements 18 are connected and molded to forma unitary construction that when head protector 11 is impacted by anobject the force of the impact is distributed throughout the network ofconnected triangular elements 16 and rectangular elements 18 thusreducing the pressure from the impact on the head of the user. Thelength of one edge of a triangular element 16 or a rectangular element18 is at least 9.5 mm (⅜ inch).

FIG. 12 shows a front view of head protector 11. Lower lateral element17 is designed to run parallel and above the user's eyebrows, curvedownward both sides of the head over the temples, and then complete thecircuit behind the head. The network or mesh of elements formingpolygons including triangular elements 16 and rectangular elements 18protecting the circumference about the head defined by the upper andlower boundaries of the forehead, temples on both sides of the head, andthe crown of the head above the upper boundary of the forehead.

FIG. 13 shows a left side view of head protector 11 as worn by a user.Lower lateral element 17 is shown positioned above the user's eyebrows,passing over the user's temples, and arching above the ear beforepassing about the back of the user's head. The network or mesh ofelements including triangular elements 16 and rectangular elements 18protecting the circumference about the head defined by the upper andlower boundaries of the forehead, temples on both sides of the head, andthe crown of the head above the upper boundary of the forehead.

FIG. 14 shows a third embodiment of a head protector identified asreference 13. Headgear enhancer or head protector 13 is designed toprotect the circumference about the head defined by the upper and lowerboundaries of the forehead and the temples on both sides of the head.Head protector 13 uses a network of geometric shapes that are for themost part either triangular elements 16 or rectangular elements 18.Rectangular elements 18 protect those portions of the head that isrelatively smooth or flat while triangular elements 16 protect thoseportions of the head that includes sharper slopes or contours. Thecombinations of molded triangular elements 16 and rectangular elements18 may be altered to accommodate varying head shapes from children toadult. The edges of a triangular element 16 or a rectangular element 18have a durometer of 15-60 Shore A Hardness. The triangular elements 16and rectangular elements 18 are molded of unitary construction incommunication with each other such that when head protector 11 isimpacted by an object the force of the impact is distributed to reducepressure (force/unit area) on the head in an effort to mitigate headinjury as well as mild traumatic brain injury including concussion.

FIG. 15 shows a front view of head protector 13. Lower lateral element17 is designed to run parallel and above the user's eyebrows, curvedownward both sides of the head over the temples, and then complete thecircuit behind the head. Again is shown a network of triangular elements16 and rectangular elements 18 protecting the circumference about thehead defined by the upper and lower boundaries of the forehead and thetemples on both sides of the head.

FIG. 16 shows a left side view of head protector 13 as worn by a user.Lower lateral element 17 is shown positioned above the user's eyebrows,passing over the user's temples, and arching above the ear beforepassing about the back of the user's head. Reshown is the network oftriangular elements 16 and rectangular elements 18 protecting thecircumference about the head defined by the upper and lower boundariesof the forehead and the temples on both sides of the head.

As illustrated in FIGS. 14-16, head protector 13 forms a headbandextending about the circumference of the head between the brow line andtop of the forehead with an open crown and extensions extending downwardon either side of the ears. In another embodiment not specificallyillustrated, the front extension covering the temple area is omitted.

FIGS. 17-22 illustrate protective gear enhancers configured todistribute impact forces and reduce injury according to the disclosure.Similar to the previously described embodiments, the protective gearenhancers include a connected network or mesh of elements molded of aresilient material such as previously described to form a single unitaryconstruction. The embodiments illustrated in FIGS. 17-22 may be securedto or beneath protective gear having a hard outer shell. Enhancersillustrated in FIGS. 17-21 may be secured by associated straps,adhesive, hook/loop, or other means within a mask or helmet, such as abaseball catcher's helmet or a baseball catcher's mask, or umpire'smask, for example. Unlike the protective headgear embodimentsillustrated in FIGS. 1-16, the enhancers of FIGS. 17-21 extend onlyacross the forehead of the user and are secured in place by an outerhelmet or mask. The enhancers of FIGS. 17-21 are configured to cover theforehead and extend from approximately tangent to the eye sockets acrossthe forehead.

The enhancer in the embodiment of FIG. 22 may be secured beneath abaseball batter's wrist protector, for example.

FIG. 17A illustrates a protector or headgear enhancer according to oneembodiment of the disclosure. FIGS. 17B and 17C illustrate side and rearviews, respectively, of the embodiment of FIG. 17A installed in abaseball catcher's helmet.

FIGS. 18-20 illustrate alternative embodiments of a protector orheadgear enhancer according to the disclosure. The alternativeembodiments illustrated include various geometries to accommodateplacement within various types and styles of helmets or headgear such asworn in baseball or hockey, for example.

FIG. 21A illustrates another embodiment of a protector or headgearenhancer according to the disclosure that may be secured within a facemask or protector. FIG. 21B is a rear view illustrating the headgearenhancer embodiment of FIG. 21A installed in a baseball catcher's orumpire's mask, and FIG. 21C is a front view illustrating the embodimentof FIG. 21A in use in a baseball catcher's or umpire's mask.

While exemplary embodiments are described above, it is not intended thatthese embodiments describe all possible forms encompassed by the claims.The words used in the specification are words of description rather thanlimitation, and it is understood that various changes can be madewithout departing from the spirit and scope of the disclosure. Aspreviously described, the features of various embodiments can becombined to form further embodiments of the invention that may not beexplicitly described or illustrated. While various embodiments couldhave been described as providing advantages or being preferred overother embodiments or prior art implementations with respect to one ormore desired characteristics, those of ordinary skill in the artrecognize that one or more features or characteristics can becompromised to achieve desired overall system attributes, which dependon the specific application and implementation. These attributes mayinclude, but are not limited to cost, strength, durability, life cyclecost, marketability, appearance, packaging, size, serviceability,weight, manufacturability, ease of assembly, etc. As such, embodimentsdescribed as less desirable than other embodiments or prior artimplementations with respect to one or more characteristics are notoutside the scope of the disclosure and can be desirable for particularapplications.

What is claimed is:
 1. A protective head gear, comprising: a network ofsegments that define the outer boundary of triangular elements andrectangular elements; said network configured to cover the circumferenceabout the head defined by the upper and lower boundaries of theforehead, the temples on both sides of the head, and the crown of thehead; said segments molded together to form a single, unitaryconstruction and configured to distribute forces resulting from animpact; said segments having an outer diameter ranging from 5-17 mm andhaving a hardness ranging from 15-60 Shore A Hardness scale.